Method for constructing low cost housing units

ABSTRACT

A METHOD OF CONSTRUCTION FOR LOW COST HOUSING UNITS IN WHICH A PLURALITY OF PREASSEMBLED TRANSVERSE POST AND BEAM FRAME UNITS ARE ERECTED ON A FOUNDATION TO PROVIDE THE SUPPORT FOR A COMPLETE HOUSING MODULE. THE FRAME UNITS ARE SPACED TO FACILITATE THE USE OF COMMERCIALLY AVAILABLE SIZES OF PRE-CUT PANELS TO FORM INTERIOR AND EXTERIOR WALLS.

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mvmwnn JOSEPH J. TOSCANO ()RNEYS United States Patent 3,609,936 METHODFOR CONSTRUCTING LOW COST HOUSING UNITS Joseph J. Toscano, 510 B 52Bypass W., West Lafayette, Ind. 47906 Filed Feb. 20, 1970, Ser. No.13,059 Int. Cl. E04h 1/04 US. Cl. 52741 Claims ABSTRACT OF THEDISCLOSURE A method of construction for low cost housing units in whicha plurality of preassembled transverse post and beam frame units areerected on a foundation to provide the support for a complete housingmodule. The frame units are spaced to facilitate the use of commerciallyavailable sizes of pre-cut panels to form interior and exterior walls.

BACKGROUND OF THE INVENTION This invention relates to improvements inconstruction techniques for low cost housing units and moreparticularly, it concerns a modular post and beam constructionparticularly suitable for use in wood frame structures, it beingcontemplated that various features of the invention may be adaptable toconstruction employing materials other than wood, such as for exampleprestressed concrete.

Currently there is an acute need throughout the urban and suburban areasof the United States for housing which is low in cost, comfortable andaesthetically appealing to meet both the economic and socialrequirements of the times. Although various types of building designsand many diverse techniques for their construction have been devised,few if any are acceptable both from the standpoint of cost and aestheticappeal, the latter criterion being especially important from thestandpoint of creating an adequate demand for commercial reality.

The use of traditional building materials such as wood, brick, plasteror materials similar in all physical characteristics to these buildingmaterials has been recognized by the housing industry as prerequisite tocommercial success presumably because of the innate warmth and aestheticappeal stemming from the mere fact that their use is traditional. Inmost areas of the country, wood frame construction remains lower in costthan brick or masonry construction as a result of both material andlabor costs. The fact remains however, that even with most forms of woodframe construction presently available, a significant amount ofon-the-job labor is required in relation to unit space of housingprovided, thereby posing serious problems to the accomplishment of lowcost construction even with wood. This latter factor is particularlyprevalent in the finishing of conventional mill work and the like torender the dwelling livable in an aesthetic sense.

SUMMARY OF THE PRESENT INVENTION In accordance with the presentinvention, many of the problems presented by the conventional frameconstruction techniques are solved by the employment of a cubic buildingmodule erected by arranging a series of substantially identical post andbeam frame units in aligned spaced relation, the frame unitsconstituting the sole structural support for fioors, walls and roofing.[Each of the frames includes an assembly of a lower sill, at least twoposts having their bases fixed at the ends of the sill, a cap securedbetween the upper ends of the posts and at least one intermediate joistextending between and supported from the posts, the precise number ofjoists in each frame depending on the number of stories contemplated forthe See building to be constructed. The frames preferably arepreassembled either near the building site or at a remote factory andduring construction are placed on a foundation in parallel spacedrelation by using spacing members extending between the aligned posts ofadjacent frames at the levels of respective sills, joists and caps. Byselecting an appropriate spacing between respective frames, commercially available panels may be used to close walls, both interiorlyand externally. Floors are formed by using planking extending betweenthe sills and joists of the frame members placed on the foundation.

Preferably the sills, joists and caps used in the construction techniqueaccording to this invention are readily available 6" by 8" beams whereasall posts employed are 6" by 6 in cross-sectional dimension. It will beappreciated, however, that the precise dimensioning of the lumber willvary depending on the size of unit to be constructed in order to developadequate structural strength. Also, the use of lumber having at leastone common dimension, such as the example given, facilitates the use ofa common clip for connecting the structural members of each frame.

It is therefore a principal object of the present invention to provide alow cost, yet attractive housing unit as well as a unique method for itsconstruction. Other objects of the present invention includes thereduction to a minimum of on-the-job time required in cutting orotherwise shaping of members used in construction; a facility for theuse of commercially available cut panels for walls, ceilings and like;the provision of a modulate building unit which may be assembled withother similar modules to provide a housing structure of substantialcapacity; the provision of a unique connecting clip for post and beamtype construction techniques; and the provision of a housing unit whichfacilitates the erection of an aesthetically appealing dwelling. Stillother objects of the invention will become apparent from the detaileddescription of a preferred embodiment to follow below taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary perspectiveview illustrating the exterior appearance of a housing module formed inaccordance with the present invention incorporated as a unit in a largerstructure shown partly in phantom lines;

FIG. 2 is a plan view or layout of the first floor of one design of abuilding module in accordance with the present invention;

FIG. 3 is a fragmentary cross-section taken on line 3-3 of FIG. 2;

FIG. 4 is a floor plan or layout of the second story of the buildingshown in FIG. 1;

FIG. 5 is an enlarged fragmentary cross-section taken on line 55 of FIG.4;

FIG. 6 is a fragmentary perspective view, partially cut awayillustrating the framing technique in accordance with the presentinvention;

FIG. 7 is an end view illustrating the preferred form of connector usedin accordance with the present invention;

FIG. 8 is a side view of the connector shown in FIG. 7; and

FIG. 9 is a perspective view of the connector illustrated in FIGS. 7 and8 of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in FIGS. 1-4of the drawings, the housing unit module of this invention is designatedgenerally by the reference number 10 and is characteristically cubic ingeneral exterior configuration. Although in FIG. 1, only one module isshown in solid lines, a plurality of such modules, each constituting afamily housing unit, may be arranged much in the manner of conventionaltownhouses where the modules are offset or staggered depending on theplot of ground on which they are placed. Although the number of floors,as Well as the layout of each floor may vary without departingsignificantly from the basic module 10, a two-story structure supportedon a foundation 12 is used in the embodiment shown. The

plans for the first floor 14 and second floor 16, in accordance with theparticular embodiment illustrated, are shown respectively in FIGS. 2 and4 of the drawings. Also, it will be noted that the first and secondfloors 14 and 16 are interconnected by a stairwell 18. Apart from thelocation and size of the stairwell 18, as will become more apparent fromthe description to follow below, any arrangement of rooms may beprovided on the respective first and second floors. All interior wallssuch as the partitions 20 in FIG. 2 and the interior partitions 22 inFIG. 4 are non-load bearing and hence can be relocated to suit thedesired size and number of rooms for the intended use of the dwellingunit module 10.

The structural support or framing for the dwelling unit 10 may be mostclearly understood by reference to FIG. 6 in conjunction with FIGS. 2-4of the drawing. As shown in FIG. 6, the dwelling unit 10 includes aseries of transversely disposed frame units 24, 25, 26, 27, 28, 29, 30and 31 to be supported directly on the foundation 12 in equally spacedincrements along with the length of the foundation. Although the preciseorganization of structural members in each of the frames 24-31 maydiffer slightly depending on the location of a particular frame Withinthe building module, each is formed of pre-cut structural membersincluding basically a lower sill 32, a pair of end posts 34 having theirlower ends fixed to the sills 32, an intermediate joist 36 supported atits ends from the posts 34 and a cap 38 supported on the upper ends ofthe post 34. To accommodate the stairwell 18, the joists 36 in theframes 27 and 28 are cut short and supported by short posts 40 as shownin FIG. 6. Also, a short interior post 42 may be employed in the frame26 to provide additional support for the upper end of the stairs in thestairwell 18 and an appropriate header (not shown) may be used to frameout the stairwell 18. In the end frames 24 and 31, auxiliary short posts44 and 46 are employed principally to carry the aesthetic post and beamdesign throughout the ends of the housing module 10. Although the posts44 and 46 add a measure of structural integrity to the framework of themodule, they are not essential and hence can be removed to facilitatedoorways and the like as shown for example at 47 in FIG. 2 of thedrawing.

In the erection of the module on the foundation 12, each of the frames2431 are first assembled by using the connectors 48 shown in FIGS. 7-9of the drawings. The connectors are of L-shaped configuration to definea vertical leg 50 connected to a horizontal leg 52 by spot welds 54through overlapping tabs 56 and 58 formed as extensions of the sideflanges 59 of the channel shaped cross section of each leg 50 and 52.The securement of the two channel shaped leg portions is augmented by aseam Weld at the juncture 60 of the bases or webs 61 in each legportion. The dimension of the clips is selected to conform preciselywith the exterior of the post and beam members used in the frames 24-31.As above mentioned all post members in the unit are conventional 6 inchby 6 inch hemlock or fir posts whereas all beam members are of similarconstruction lumber 6 inches by 8 inches in cross sectional dimension.Thus to secure the caps 38 to the upper ends of the posts 34, the clips48 are inserted at the inside juncture of these members, as shown inFIGS. 7-9, and secured in place by nails 62 extending throughappropriately located holes formed in the flanges and webs of the clip.In this manner, the individual members of the frame will be securedfirmly one to the other in a manner apparent by reference to thedrawing. Also it is contemplated that the other members of each framemay be connected in similar fashion by use of the clips 48 in the mannerdescribed above. 5

Once the individual frames 24-31 have been assembled using the clips 48,the framework for the module 10 is erected by placing an end frame, forexample the frame 24, at its proper location on the foundation 12. Eachsuccessive frame is then similarly placed on the foundation with thespace between frames being determined by spacers 64, 66 and 68 extendingbetween the end posts 34 of adjacent frames at the levels respectivelyof the sills 32, joists 36 and caps 38. The spacers 64, 66 and 68 are,in the embodiment shown, formed from conventional 2 inch by 4 inchlumber assembled to provide a box-like configuration as shown in FIG. 6of the drawings. Because of the reduced lateral dimension of the spacers46, they will be recessed slightly from the exterior and interior facesof the posts 34 to facilitate placement of wall panels between the postsand flush therewith in a manner to be described below. Also it will beappreciated that the spacers may be secured in place by conventionalnailing techniques.

After all of the frames 24-31 have been erected to the configurationillustrated in FIG. 6 of the drawings flooring 69 is laid in a directionperpendicular to the direction of the sills 32 and joists 36. As shownin FIG. 6, the flooring for both the first floor and the second floor is2 inch fir or pine plan'king which may be finished directly to achievethe desired aesthetic appearance and also lend structural integrity ofthe framing structure. A roof structure 70 of plywood panels 72 coveredby asphalt 74 or other suitable compositions and an aggregate such asgravel is applied over the caps 38. Once the flooring planks 69 are inplace interior portions such as the walls 20 and 22 may be installedusing conventional techniques. g E

As shown in FIG. 5 of the drawings, the exterior walls of the dwellingunit are formed by panels 76 selected to achieve the desired aestheticappearance of the building. Because of the uniformity of spacing betweenthe frames 24-31, the panels 76 may be pre-cut and preferably 4 feet by8 feet in size to enable adaptability of the most prevalent size plywoodpanels. The panels 76 are merely secured in place at their tops andbottoms by nailing directly to the spacers 64, 66 or 68 and along theirsides by cleats (not shown) nailed to the posts 34. Appropriate facingtrim 78 may be fixed over the ends of the paneling 76 to achieve theappearance of the building shown in FIG. 1 of the drawings.

The interior Wall surfaces for the building unit may include panels 80of gypsum board, plywood or the like affixed in a manner similar to theexterior panels 76 as shown in FIG. 5 of the drawings. The panels 80 mayextend between the posts 34 to achieve an open beam appearance or theymay be secured over the interior faces of the posts to provide acontinuous wall surface if desired. Also as shown in FIG. 5, theceilings for the rooms on the respective first and second floors mayalso be finished to achieve an open beam appearance. Insulation 82 isprovided between the interior and exterior wall panels to provideprotection against temperature extremes and as well as a sound barrier.

Thus it will be appreciated that by this invention, an improved low-costhousing unit and method for its construction is provided by which theabove-mentioned objectives are completely fulfilled. Also, it will beappreciated that variations may be made in a disclosed embodimentwithout departing from the true spirit and scope of this invention.Accordingly, it is expressly intended that the foregoing description isillustrative of a preferred embodiment, not limiting, and that the truespirit and scope of the present invention be determined by reference tothe appended claims.

I claim:

1. The method of constructing a building comprising the steps of:assembling a plurality of frames each having a sill, at least twovertical posts having the bases thereof fixed at opposite ends of saidsill, a cap supported on the upper ends of said posts and at least onejoist supported by said posts and extending in parallel spaced relationbetween said sill and said cap, placing said frames on a foundation inparallel spaced relation so that the posts on the ends of said sills inthe respective frames are aligned, fixing the spaced relationship ofsaid frames by securing horizontal spacing members between the alignedposts of adjacent frames at the levels of said sills, joists and capsrespectively, placing flooring planks on said sills and said joistsbetween said spaced frame, and placing roofing on said caps.

2. The method recited in claim 1 including assembling said frames usingpre-cut construction lumber to form said sills, posts, joists and caps,said lumber having one common dimension to provide substantially flushsurfaces on opposite sides of each frame.

3. The method recited in claim 2 wherein said sills, joists and caps areformed from lumber having a cross section on the order of six inches byeight inches and wherein said posts are formed from lumber having crosssectional dimensions on the order of six inches by six inches.

4. The method recited in claim 2 including the step of connecting themembers of each frame by inserting an L-shaped clip of channel sectionat the juncture of the respective members in each frame and nailing saidclip to said members.

5. The method recited in claim 1 including the step of installingpre-cut wall panels between the posts of adjacent frames.

References Cited UNITED STATES PATENTS 2,480,330 8/1949 Kump 52-7453,008,195 11/1961 Coffey 52-650 3,393,483 7/1968 Waillon 52-74 3,461,6338/1969 Ziegelman 52-79 JOHN E. MURTAGH, Primary Examiner U.S. Cl. X.R.52-236, 650

